Horizontally and vertically extendable building structure module

ABSTRACT

There is provided a horizontally and vertically extendable building structure module that includes a panel, a structural frame and one or more beams. The panel may be designed to form or set into a floor, ceiling, wall, window, door or any other components that may cover surface of the building. The structural frame may be designed to provide the structural shape and strength and hold the panels. The beams may be designed to connect and align the structural frame. The horizontally and vertically extendable building structure module is configured to build a building structure without additional structural support. Because of the minimized number of components for the building structure, time and cost for building construction may be reduced.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. Patent Application Ser. No. 62/849,303 entitled “Horizontally and Vertically Extendable Building Structure Module” filed May 17, 2019, which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention pertains to the field of construction of buildings, and in particular to modular building systems to construct building structures with a limited number of types of components.

BACKGROUND

Buildings are generally constructed through long established processes. The entire building construction may take several months or even several years depending on building size and complexity of building design.

Unfortunately, the long process of building construction is often delayed for several reasons such as weather, fund insufficiency and change of building plan. Moreover, the delayed construction schedule may cause increase of construction cost. As such, the delay of construction schedule has become one of the main concerns in construction industry, especially in developed countries where labour cost is expensive.

In order to finish construction project within schedule and budget, the construction industry has made several efforts and attempted a number of methods reducing building construction time. One of the attempts is use of pre-fabricated components for buildings construction. Modularized building components are pre-fabricated at factory, delivered to the construction site and then assembled to form a larger component of the building. This method is generally referred to as modular construction.

However, components used in currently available modular construction are typically designed for permanent structures, thus will only allow limited flexibility in use and design. Using these components, the modular construction would result in most buildings being permanent structures, which would be eventually demolished for new and different use cases.

While there are some interlocking modular structures constructed as temporary or semi-permanent structures, for example display stands at exhibitions and showroom accommodations, most of currently available interlocking modular structures are designed to be one-story or one-level.

Therefore there is a need for new building construction components that obviate or mitigate one or more limitations of the prior art.

This background information is provided to reveal information believed by the applicant to be of possible relevance to the present invention. No admission is necessarily intended, nor should be construed, that any of the preceding information constitutes prior art against the present invention.

SUMMARY

An object of embodiments of the present invention is to reduce time required for building construction by minimizing the number of components and processes needed to establish buildings with focus on interior rooms. The components and processes would allow building structures to have ultimate flexibility as well as continuous changes and adjustments in use and design. In accordance with an aspect of the present invention, there is provided a horizontally and vertically extendable building structure module including a panel and a structural frame with one or more elongated connectors on each lateral side, the structural frame being configured to hold the panel. The building structure module further including one or more beams with one or more elongated mating connectors on each lateral side, the beams being configured to connect and align the structural frames by interconnecting the elongated connector and the elongated mating connector. The building structure module is configured to build a building structure without additional structural support.

In some embodiments, the one or more elongated connectors is an elongated protrusion extending outwardly and wherein the one or more elongated mating connectors is an elongated groove.

BRIEF DESCRIPTION OF THE FIGURES

Further features and advantages of the present invention will become apparent from the following detailed description, taken in combination with the appended drawings, in which:

FIG. 1 illustrates, in a front view, a panel shaped in rectangle, in accordance with embodiments.

FIG. 2A illustrates, in a front view, a vertical structural frame, in accordance with embodiments.

FIG. 2B illustrates, in a cross section view, a lateral side of a vertical structural frame, in accordance with embodiments.

FIG. 2C illustrates, in a front view, a horizontal structural frame, in accordance with embodiments.

FIG. 2D illustrates, in a cross section view, a lateral side of a horizontal structural frame, in accordance with embodiments.

FIG. 3 illustrates, in an elevation view, a beam configured to connect two structural frames, in accordance with embodiments.

FIG. 4A illustrates, in a side view, two rectangular horizontal structural frames connected each other in horizontal using a beam, in accordance with embodiments.

FIG. 4B illustrates, in a perspective view, a filling bar covering a channel between two rectangular horizontal structural frames, in accordance with embodiments.

FIG. 5 illustrates, in a side view, a horizontal structural frame and a vertical structural frame being perpendicularly connected through a beam, in accordance with embodiments.

FIG. 6 illustrates, in a perspective view, three rectangular structural frames connected in series using beams, in accordance with embodiments.

FIG. 7 illustrates, in a perspective view, a framework of one-story building constructed, in accordance with embodiments.

FIG. 8 illustrates, in a perspective view, a framework of a multi-story building constructed, in accordance with embodiments.

FIG. 9 illustrates, in a perspective view, a variety of covers associated with a framework of multiple-story building constructed in accordance with embodiments.

FIG. 10A illustrates a perspective view of an external corner cover in accordance with embodiments.

FIG. 10B illustrates a perspective view of an internal corner cover in accordance with embodiments.

FIG. 10C illustrates a perspective view of an edge cover in accordance with embodiments.

FIG. 11A illustrates a perspective view of a horizontal cover in accordance with embodiments.

FIG. 11B illustrates a perspective view of a vertical cover in accordance with embodiments.

FIG. 11C illustrates a side view of a horizontal cover in accordance with embodiments.

FIG. 11D illustrates a side view of a horizontal cover connected to a beam connecting two horizontal structural frames, in accordance with embodiments.

FIG. 11E illustrates an elevation view of a vertical cover in accordance with embodiments.

FIG. 11F illustrates an elevation view of a vertical cover connected to a beam connecting two vertical structural frames, in accordance with embodiments.

FIG. 12A illustrates, in an exploded perspective view, a panel to be secured into a structural frame using a chemical locking system, in accordance with embodiments.

FIG. 12B illustrates, in a perspective view, a chemical locking system attached to a structural frame, in accordance with embodiments.

FIG. 12C illustrates, in a perspective view, a chemical locking system attached to a structural frame, in accordance with embodiments.

FIG. 12D illustrates, in a cross section view, a panel secured into a structural frame using a chemical locking system, in accordance with embodiments.

It will be noted that throughout the appended drawings, like features are identified by like reference numerals.

DETAILED DESCRIPTION

Embodiments of the present invention provide a building modular structure that can reduce time required for building construction. Time reduction for building construction can be achieved by minimizing the number of components and processes needed to construct buildings. The building structure module disclosed herein includes three structural components which, without additional structural support, enable to build structural rooms, multi-room areas, multi-story floor spaces or an entire building. Being fully modular, the structure module also allows building structures to have ultimate flexibility as well as continuous changes and adjustments in use and design.

According to embodiments, a horizontally and vertically extendable building structure module may comprise a panel, a structural frame and one or more beams. The panel may be designed to form or set into a floor, ceiling, wall, window, door or any other components that may cover surface of the building. The structural frame may be designed to provide the structural shape and strength and hold the panels. The beams may be designed to connect and align the structural frame.

As noted above, the panel may form or set into a floor, ceiling, wall, window, door or any other components that may cover surface of the building. The panel can be made of various materials such as wood, concrete, glass or metal. While some panels may be composed of a single material type, some other panels may be composed of combination of two or more material types. The material used for each panel may depend on the use of the panel. For example, the panel manufactured as a wall of building module may be composed of wood, mineral compounds and/or polystyrene foam for the purpose of insulation and humidity control.

According to embodiments, a panel is designed to be affixed to the frame. In some embodiments, the panel may be affixed to the inside of the structural frame (e.g. the edge of the panel may be inwardly attached to four lateral sides of the rectangular structural frame) so that at least part of the panel may stay inside of the structural frame for the attachment. In some embodiments, the panel may be affixed to the front or back of the structural frame (e.g. front or back of four lateral sides of the rectangular frame). In some embodiments, a panel may be affixed to the structural frame using a chemical locking system or chemical mixtures (e.g. glue, polyurethane foam, etc). In some embodiments, a panel may be affixed to the structural frame using threaded rods. In some embodiments, a panel may be affixed to the structural frame without using extra elements. For example, a panel may be captured within the frame using construction/assembly techniques such as a woodworking technique.

In various embodiments, panels may be available in various sizes and designs as there are various structural frames available in a plurality of size and design. For example, there may be two different structural frames due to different structural strength requirements—horizontal building components (e.g. floor, ceiling, roof) and structural frames for vertical building components (e.g. wall, window, door). Due to different size and/or design of the two structural frames, there should be two different panels—one fitting into structural frames for horizontal building components and the other fitting into structural frames for vertical building components.

According to embodiments, the building structure module includes structural frames providing architectural shape and strength to the building module. The structural frames are generally designed symmetrically in order to provide sufficient structural strength to the building module as well as to maximize the extendibility of the building structure module. For that, in various embodiments, the rectangular structural frames are provided. The rectangular structural frames, due to the quadrilateral shape with four right angles, may maximize extendibility of the building modules vertically and horizontally. For example, the building can be extended partly or entirely at any time without prior consideration of this extension. As such, rectangular structural frames are preferred in shape in various embodiments. However, structural frames can be formed in other polygonal shapes, for example square, if required.

In some embodiments comprising rectangular structural frame, the length of two alternate sides of the structural frame is approximately three times longer than the length of the other two alternate sides. When the structural frame is used for vertical elements (e.g. wall), the longer sides may be vertical sides of the structural frame (e.g. the two lateral sides of the frame) and the shorter sides may be horizontal sides of the structural frame (e.g. the top and bottom of the frame). However, the ratio between two adjacent sides (e.g. ratio between the length and width of the frame) can be varied depending on one or more factors, for example building layout or required structural shape and strength. In one example, a frame may be shaped in square thus the length of two alternate sides equates to the length of the other two alternate sides.

In some embodiments, the structural frames have a plurality of sizes and/or designs. For example, there may be one type of structural frames for horizontal components such as floors, ceilings and roofs, and another type of structural frames for vertical components such as walls, doors and windows. In such cases, due to different size and design (e.g. different design in shape or structure), horizontal structural frames may be able to hold only panels acting as a horizontal elements such as floors, ceilings and roofs; and vertical structural frames may be able to hold only panels acting as a vertical structural components such as walls, doors and windows.

According to embodiments, a structural frame with one or more elongated connectors on each lateral side, the structural frame being configured to hold the panel. The building structure module further includes one or more beams with one or more elongated mating connectors on each lateral side, the beams being configured to connect and align the structural frames by interconnecting the elongated connector and the elongated mating connector.

According to embodiments, a structural frame may have one or more elongated protrusions on each side of the structural frame. The elongated protrusion of the structural frame may be extruded outwardly in order to extend structural module by assembling two structural frames together with a connecting beam. In some embodiments, each side of the structural frame may be initially manufactured without elongated protrusions and the elongated protrusions may be welded to each lateral side of the structural frame later. In some embodiments, structural frames or each side of the structural frame may be manufactured through moulding process using a mould container. In this case, the casting released from the mould container would be the structural frame or lateral side of the structural frame with elongated protrusion(s).

According to embodiments, a structural frame is configured to be interlocked with a beam. The beam is configured to connect two adjacent structural frames. Specifically, elongated protrusion(s) of the structural frame is fitted into elongated groove(s) of the connecting beam to connect the two components together. In order to keep the two joining components being engaged or interlocked, a portion of the elongated protrusion may be extruded outwardly, in that top portion or middle portion of the elongated protrusion may be larger than the bottom portion of the protrusion. In one example, the head portion of the elongated protrusion is designed to be larger than body portion of the elongated protrusion (e.g. T-slot rail). In another example, the elongated protrusion is shaped in a cross (e.g. “+”).

In various embodiments, the elongated protrusion is designed to be complementary to the elongated groove in shape in order to promote two joining components being interlocked. Because of this complementary shape, the beam is able to more firmly connect and align the structural frames by mating the elongated protrusion and the elongated groove.

According to embodiments, the building structure module includes one or more beams which are configured to connect and align the structural frames. For the connection with the structural frame, beams are configured to have one or more elongated grooves. The elongated grooves of the beam are designed to embrace the elongated protrusion of the structural frame. In various embodiments, the elongated groove is designed to be complementary to the elongated protrusion in shape. Because of this complementary shape, the elongated protrusion of the structural frame and the elongated groove of the beam can be mated, and accordingly the beam can connect and align the structural frame.

According to embodiments, the building structure module includes structural frames providing architectural shape and strength to the building module. Generally speaking, the shape of the beam is similar to a prism bar with two parallel polygonal bases. In various embodiments, the shape of the two parallel bases may be similar to a regular polygon (i.e. a polygon that is equiangular and equilateral) so that every lateral side of the beam can be identical. For example, in some embodiments, the overall shape of the beam may be similar to a prism with square bases. In some other embodiments, the overall shape of the beam may be similar to a prism with regular octagon bases.

According to embodiments, the elongated groove is located on each lateral side of the beam. The elongated groove(s) on every lateral side may maximize extendibility of the building modules in that the building can be extended at any time without prior consideration of this extension. Specifically, in various embodiments, there may be one or more elongated grooves that are not connecting structural frames. These unused elongated grooves can be used to extend the building without demolishing existing building structural module. The extension can be performed by simply mating the elongated protrusion of the structural and the elongated groove of the beam. According to embodiments, the unused elongated grooves (i.e. elongated grooves that are not connecting structural frames) can be covered or sealed using covers or filling bars. The cover and the filling bar are configured to hide the channel (sunken space) between two adjacent structural frames, thereby providing a more seamless look on walls or floors (e.g. a more flattened floor surface or wall surface). The cover and the filling bar can also provide functional purpose, for example enclosure, weather proofing, sound proofing, heat insulation, an isolation effect between adjacent spaces (e.g. adjacent rooms) or any combination thereof. The cover and the filling bar may be configured to connect with the beam via the unused elongated grooves. For example, the cover and the filling bar may include an elongated protrusion which can be inserted into the unused elongated groove of the beam.

Furthermore, since there are elongated grooves on every lateral side of the beam, the building structural module can be extended, by assembling structure frames and beams, in any direction. Thus, the building can be extended even if the building is constructed without prior plan for building extension. In other words, the building can be extended at any time, even when the construction of the building structure is complete without contemplating potential building extension.

According to embodiments, the building structure module is configured to build a building structure without additional structural support. Accordingly, each component of the building structure module, especially structural frames and beams, should be designed to have structure providing sufficient strength and durability for heavy load of the building structure. For that, in various embodiments, the structural frames and the beams may be designed to have (partly) hollow area. The hollow area in the structural frames and the beams reduce material cost and provides sufficient structural strength to endure load stress and good resistance to twisting torques.

According to embodiments, each component of the building structure module should be manufactured using appropriate materials providing sufficient structural strength and durability. For example, structural frames and connecting beams may be made of metal such as steel, aluminum, or alloy. The panel may be made of various materials such as wood, concrete, glass or metal. In some embodiments, the panel may be composed of combination of two or more material types to contain several beneficial properties. For example, the panel manufactured for a floor system of building module may be composed of concrete with steel inserts. In this case, the concrete will provide strength and durability and the steel inserts will allow installing columns onto sleeves at factory and act as an anchor point to attach other building module(s).

According to embodiments, the way the structure module is designed enables the structural frame and the beam being repeatedly (i.e. multiple times) connected and disconnected in an efficient manner. The structural frame and the beam can be repeated connected and disconnected by mating and unmating the elongated protrusion of the structural frame and the elongated groove of the beam. To mate or unmate multiple times, both the elongated protrusion and the elongated groove may be composed of metals with good strength, durability and rigidity.

FIG. 1 illustrates, in a front view, a panel shaped in rectangle, in accordance with embodiments. Referring to FIG. 1, the panel 100 may be shaped in rectangle. The panel 100 may be composed of the honeycomb 130 surrounded by the internal frames 120. The combination of the honeycomb 130 and the internal frames 120 will reduce the load of the panel 100 while providing sufficient structural strength and durability. In some embodiments, inside of each hexagonal prism of the honeycomb 130 may be hollow. In some embodiments, inside of each hexagonal prism of the honeycomb 130 may be filled with insulating materials to prevent heat loss from or heat transfer to inside of the building.

While the size of each hexagonal prismatic cell in honeycomb 130 can be varied, according to some embodiments, the size of the hexagonal prismatic cell is about 10 mm, and in some embodiments about 9.53 mm. According to some embodiments the thickness of the hexagonal prismatic cell (i.e. height of the hexagonal prism) is about 100 microns and in some embodiments, about 70 microns. The honeycomb 130 and the internal frames 120 may be covered and protected by the skin 110 to prevent the honeycomb 130 and the internal frames 120 being exposed. Thus, the skin 110 may not need to be thick. According to embodiments, the thickness of the skin 110 is between 1.5 mm and 2.5 mm.

According to embodiments, while the dimensions of the panel 100 can be varied, according to some embodiments, the thickness is about 150 mm, in some embodiments about 100 mm. According to embodiments, the width is about 920˜960 mm and the length is about 3050˜3200 mm. In various embodiments, the width of the panel may be a little less than one third of the length of the panel. The length of the panel 100 may be slightly less than the height of one floor especially when the panel is used as a wall panel. This is because, in various embodiments, the length of the structural frame holding the panel 100 may be substantially equivalent to the height of the floor. According to embodiments, each dimension of the panel 100 may not be greater than each dimension of structural frame as the panel 100 are configured to be fitted into the structural frame.

In some embodiments, all components of the panel 100 may be made of metals to provide sufficient structural strength and durability. For example, the honeycomb 130 may be made of 3003 aluminum alloy and the skin 110 and the internal frames 120 may be made of 6061 T6 aluminum.

FIG. 2A illustrates, in a front view, a vertical structural frame, in accordance with embodiments. Referring to FIG. 2A, the vertical structural frame 200 may be shaped in rectangle. The structural frame 200 may be composed of four lateral sides 210, 220, 230 and 240. Each of the lateral sides 210, 220, 230 and 240 may have the outwardly extruded part in the middle throughout their lengthways, as illustrated in FIGS. 2A and 2B. The elongated protrusions 211, 221, 231, 241 may be externally extruded from the extruded part of four lateral sides 210, 220, 230 and 240, respectively. The elongated protrusions 211, 221, 231, 241 are designed to interlock with the elongated groove of the beams. For that, the head of the elongated protrusions 211, 221, 231, 241 are larger than their body and extruded in two directions (e.g. left and right). The elongated protrusions 211, 221, 231, 241 may be complementary to the elongated grooves of the mating beams, in shape and size. The shape of the elongated protrusions 211, 221, 231, 241 may be identical to one another. The cross section view of the lateral side 210 with the elongated protrusion 211 thereon is illustrated in FIG. 2B.

According to embodiments, while the dimensions of the structural frame 200 can be varied, in some embodiments, the width is about 1040 mm and the length is about 3190 mm. The length of lateral side may be greater than the length of elongated protrusion thereon. For example, the lengths of the four lateral sides 210, 220, 230, 240 may be approximately 70 mm greater (35 mm each side) than the lengths of the elongated protrusions 211, 221, 231, 241, respectively.

In various embodiments, the preferred width of the structural frame may be a little less than one third of the length of the structural frame. The length of the structural frame 200 may be substantially equivalent to the height of one floor. According to embodiments, dimensions of the structural frame 200 may be slightly greater than dimension of the mating panels as the panels are configured to be fitted into the structural frame 200.

FIG. 2C illustrates, in a front view, a horizontal structural frame, in accordance with embodiments. Referring to FIG. 2C, the horizontal structural frame 250 may be shaped in rectangle. The structural frame 250 may be composed of four lateral sides 260, 270, 280 and 290. Unlike the structural frame 200, the lateral sides of the structural frame 250 may not have the extruded part in the middle throughout their lengthways. The elongated protrusions 261, 271, 281, 291 may be externally extruded from the middle of the four lateral sides 260, 270, 280 and 290, respectively. The elongated protrusions 261, 271, 281, 291 are designed to interlock with the elongated groove of the beams. For that, the head of the elongated protrusions 261, 271, 281, 291 are larger than their body and extruded in two directions (e.g. left and right). The elongated protrusions 261, 271, 281, 291 may be complementary to the elongated grooves of the mating beams, in shape and size. The shape of the elongated protrusions 261, 271, 281, 291 may be identical to one another. The cross-section view of the lateral side 290 with the elongated protrusion 291 thereon is illustrated in FIG. 2D.

According to embodiments, while the dimensions of the structural frame 250 can be varied, according to some embodiments, the width is about 1040 mm and the length is about 3250 mm. The length of lateral side may be greater than the length of elongated protrusion thereon. For example, the lengths of the four lateral sides 260, 270, 280, 290 may be approximately 70 mm greater (35 mm each side) than the lengths of the elongated protrusions 261, 271, 281, 291, respectively. In various embodiments, the preferred width of the structural frame may be a little less than one third of the length of the structural frame. Also, the dimensions of the structural frame 250 may be slightly greater than dimension of the mating panels as the panels are configured to be fitted into the structural frame 250.

According to embodiments, all components of the structural frames 200 and 250 may be made of metal to provide providing sufficient structural strength and tolerance. For example, each of the four lateral sides of the structural frames 200 and 250 and elongated protrusions thereon may be made of 6063 T6 aluminum.

FIG. 3 illustrates, in an elevation view, a beam configured to connect two structural frames, in accordance with embodiments. According to embodiments, while the design of the beam 300 can be varied, according to embodiments the shape of the beam 300 is square prism. Referring to FIG. 3, inside of the beam 300 may be (partly) hollow in order to reduce its weight. Despite of the unfilled space inside, the hollow structure section of the beam 300 still provides sufficient structural strength to endure load stress and good resistance to twisting torques. In some embodiments, the hollow space may be filled with materials such as concrete when greater rigidity is required. In some embodiments, the hollow space may be filled with insulating materials to prevent heat loss from or heat transfer to inside of the building.

Further referring to FIG. 3, each lateral side of the beam 300 have an elongated groove (e.g. elongated grooves 331, 332, 333 and 334). The elongated grooves of the beam 300 may be substantially similar to the indentation of the T-slot rail. While the indentation of the elongated groove can be varied in shape, the shape of each elongated groove should be configured to be complementary to that of the mating elongated protrusion of the structural frame (e.g. structural frame 200 in FIG. 2A and structural frame 250 in FIG. 2C).

Further referring to FIG. 3, cross-section of the beam 300 looks symmetrical with respect to the horizontal axis as well as the vertical axis. By virtue of the symmetrical structure, the beam 300 may have uniform strength characteristics and good resistance to twisting torques. The wall members 301, 302, 303 and 304 are connected each other by the reinforcing ribs. Specifically, the wall members 301 and 302 are connected by the reinforcing rib 311 and the wall members 303 and 304 are connected by the reinforcing rib 312. Also, the wall member 301 and reinforcing rib 311 are connected by the reinforcing rib 313 and the wall member 302 and reinforcing rib 311 are connected by the reinforcing rib 314. Similarly, the wall member 303 and reinforcing rib 312 are connected by the reinforcing rib 315 and the wall member 304 and reinforcing rib 311 are connected by the reinforcing rib 316.

Further referring to FIG. 3, the reinforcing ribs 311 and 312 are connected each other by the reinforcing ribs 321 and 323. The reinforcing ribs 321 and 323 are parallel to each other and may determine the depth of the grooves 331 and 333, respectively. The reinforcing ribs 313 and 314 are connected each other by the reinforcing rib 322. The reinforcing rib 322 may also determine the depth of the grooves 332. The reinforcing ribs 315 and 316 are connected each other by the reinforcing rib 324. The reinforcing rib 324 may also determine the depth of the grooves 334.

According to embodiments, while dimensions of the beam 300 can be varied upon necessity, there are preferred dimensions for each component of the beam. For example, the length of each lateral side of the beam 300 is about 68 mm. For example, the thickness of each component of the beam 300 (e.g. wall members 301, 302, 303 and 304, and reinforcing ribs 311, 312, 313, 314, 315, 316, 321, 322, 323 and 324) is about 3.3 mm. As an example, the depth of the elongated grooves 331, 332, 333 and 334 is about 10 mm.

According to embodiments, all components of the beam 300 may be made of metal to provide providing sufficient structural strength and tolerance against to twisting torques. For example, the 6063 T6 aluminum may be used to manufacture the beam 300.

FIG. 4A illustrates, in a side view, two rectangular horizontal structural frames and a longitudinal connecting beam being interlocked each other in horizontal, in accordance with embodiments. Referring to FIG. 4A, the structural frames 410 and 420 are the same or similar embodiment of the horizontal structural frame 250, illustrated in FIG. 2C. Also, the beam 430 is the same or similar embodiment of the beam 300, illustrated in FIG. 3.

Further referring to FIG. 4A, the structural frames 410 and 420 are connected each other in series through the beam 430. The elongated protrusion 411 is inserted into the elongated groove 431 so that the structural frame 410 and the beam 430 can be interlocked each other. Similarly, the elongated protrusion 421 is inserted into the elongated groove 432 so that the structural frame 420 and the beam 430 can be interlocked each other. Since the elongated grooves 431 and 432 are facing each other, the structural frames 410 and 420 are connected horizontally so that the assembled frames can be substantially flat.

According to embodiments, while the elongated grooves 433 and 434 may be left unused as illustrated in FIG. 4A, they can be used at a later time when the building layout needs to be changed. For example, the elongated groove 433 or 434 can be mated with a vertical structural frame (e.g. vertical structural frame 200 in FIG. 2A) when a wall needs to be built there. In case that the elongated grooves 433 and 434 are left unused, the channel 440 (i.e. sunken space between the structural frames 410 and 420) can be hidden and covered by a filling bar (e.g. filling bar 450), as illustrated in FIG. 4B.

Referring to FIG. 4B, the filling bar 450 has the elongated protrusion 451 to be inserted into the elongated groove 434 of the beam 430. As illustrated in the figure, the filling bar 450 is a rectangular tube with hollow inside. The hollow structure of the filling bar 450 may not cause any structural weakness as the filing bar 450 may not be designed to provide any structural strength to the building module. It may be just designed to cover the channel 440.

In order to hide and cover the channel 440 entirely, the filling bar 450 should be complementary to the channel 440 in shape and dimensions. For that, the thickness of the filing bar 450 (i.e. thickness of the rectangular prism) should be substantially equal to the depth of the channel 440. The depth of the channel may be equal to half of the difference between the thickness of the structural frame 410 (or structural frame 420) and the length of the lateral side of the beam 430. In order to make the assembled frames flat more easily, the depth of the elongated protrusion 451 should be substantially equal to the depth of the elongated groove 434. However, the elongated protrusion 451 does not have to be complementary to the elongated groove 434 in shape. In terms of length and width, the length of the filling bar 450 and the length of the elongated protrusion 451 are preferred to be substantially equal to the length of the structural frames 410 and 420. The preferred width of the filing bar 450 is substantially equal to the length of lateral side of the beam 430.

Although FIGS. 4A and 4B only illustrate two horizontal structural frames 410 and 420 connected in series using the interlocking beam 430, two vertical structural frames can be connected in series using the interlocking beam, such as beam 430, in the same or similar manner.

FIG. 5 illustrates, in a side view, a horizontal structural frame and a vertical structural frame being perpendicularly connected through an interlocking beam, in accordance with embodiments. Referring to FIG. 5, the structural frames 510 is the same or similar embodiments of the horizontal structural frame 250, illustrated in FIG. 2C. The structural frames 520 is the same or similar embodiments of the vertical structural frame 200, illustrated in FIG. 2A. The beam 530 is the same or similar embodiment of the beam 300, illustrated in FIG. 3.

Further referring to FIG. 5, the structural frames 510 and 520 are perpendicularly connected each other through the beam 530. The elongated protrusion 511 is inserted into the elongated groove 531 so that the structural frame 510 and the beam 530 can be interlocked each other. Similarly, the elongated protrusion 521 is inserted into the elongated groove 532 so that the structural frame 520 and the beam 530 can be interlocked each other. Since the elongated grooves 531 and 532 are perpendicular to each other, the structural frames 510 and 520 are connected perpendicularly. The assembled structural frames 510 and 520 may become a floor and a wall, respectively.

According to embodiments, while the elongated grooves 533 and 534 may be left unused as illustrated in FIG. 5, they can be used at a later time when the building layout needs to be changed. For example, the elongated groove 533 can be mated with a horizontal structural frame (e.g. horizontal structural frame 250 in FIG. 2B) when the building needs to be outwardly extended. If another floor (an upper or lower floor) needs to be built for the extension of the building, the elongated groove 534 can be mated with a vertical structural frame (e.g. vertical structural frame 200 in FIG. 2A).

FIG. 6 illustrates, in a perspective view, three rectangular structural frames being connected in series using beams, in accordance with embodiments. Referring to FIG. 6, the structural frames 610 and 620 are connected each other in series through the beam 640. Each of the elongated protrusions of the structural frames 610 and 620 are inserted into the mating elongated grooves of the beam 640 so that the structural frames 610 and 620 are interlocked with the beam 640, in series. Similarly, the structural frames 620 and 630 are connected each other in series through the beam 650. Each of the elongated protrusions of the structural frames 620 and 630 are inserted into the mating elongated grooves of the beam 650 so that the structural frames 620 and 630 are interlocked with the beam 650, in series.

The beam 660 is interlocked with structural frames 610, 620 and 630 to further extension of the building structural module. Similarly, the beam 670 is interlocked with structural frame 610 to further extension of the building structural module. As each of the beams 660 and 670 has elongated grooves on every lateral side, a new structural frame can be connected to the assembled frames from any direction as desired. In other words, a new structural frame can be connected to the assembled frames perpendicularly or in series.

Further referring to FIG. 6, the length of the structural frames is three times longer than their width. The length of the beam is approximately equal to the length of the structural frames. The length of the beam is approximately three times longer than the width of the structural frames. As such, one beam can be interlocked with a plurality of structural frames. For example, in FIG. 6 the beam 670 is interlocked with all of three structural frames 610, 620 and 630 in series.

FIG. 7 illustrates, in a perspective view, a framework of one-story building constructed, in accordance with embodiments. The framework 700 is built using horizontal structural frames, vertical structural frames and interlocking beams. Referring to FIG. 7, six horizontal structural frames are horizontally connected each other to compose the floor of the building and another six horizontal structural frames are horizontally connected each other to build roof of the building. Vertical structural frames are also connected each other to compose walls. The floor and the ceiling are connected by the composed walls perpendicularly using the interlocking beams.

FIG. 8 illustrates, in a perspective view, a framework of multi-story building constructed, in accordance with embodiments. The multi-story building framework 800 is an extended framework of the one-story building framework 700 shown in FIG. 7. Since every beam used for the framework 700 has one or more elongated grooves on every lateral side, a new structural frame can be inserted into any beam so that the building framework 700 can be extended wherever desired. As such, the building framework 700 is extended without prior consideration of the extension and the building framework 800 in FIG. 8 is constructed.

In some embodiments, extra assembly elements may be used to connect and hold two floors of the building together with additional strength. For example, threaded rod assemblies may be inserted from the upper floor level to the lower floor level to connect and hold the two floors together. Then, nuts or other mechanical locking elements will be threaded onto the mating threaded rod assemblies in order to tighten up the connection of the two floors.

It would be understood that upon construction of a modular building in accordance with embodiments, there may be exterior locations wherein covers may be required or desired for providing a finished look to the building and in some instances to provide a weather proofing sealing of the interconnection locations. With reference to FIG. 9, examples of covers or seals are illustrated upon interconnection with various locations of a modular building. For example, these covers can include an external corner cover 910, an internal corner cover 920, an edge cover 930, a horizontal cover 905 and a vertical cover 935. Each of these covers are configured to interconnect or mate with the frame or panel at that location thereby enabling the connection of the cover to the modular building, thereby enabling the cover to provide the desired purpose, for example enclosure, weather proofing, sound proofing, heat insulation or combination thereof. It will be readily understood that other cover configurations are possible and can be dependent on the specific configuration and interconnection of the various components used to form the modular building.

FIG. 10A illustrates a perspective view of an external corner cover in accordance with embodiments. FIG. 10B illustrates a perspective view of an internal corner cover in accordance with embodiments. FIG. 10C illustrates a perspective view of an edge cover in accordance with embodiments. FIG. 11A illustrates a perspective view of a horizontal cover in accordance with embodiments. FIG. 11B illustrates a perspective view of a vertical cover in accordance with embodiments. It will be readily understood that other configurations of each of the external corner cover, internal corner cover, edge cover, horizontal cover and vertical cover are possible and considered to be within the scope of the instant application.

FIG. 11C illustrates a side view of a horizontal cover in accordance with embodiments. According to embodiments, the horizontal cover 1110 is configured to hide and cover the channel (e.g. the sunken space) between two adjacent horizontal structural frames, thereby providing a more seamless look on floors (e.g. a more flattened floor) and can aid in minimizing potential safety concerns. The horizontal cover 1110 may also provide a functional purpose, for example enclosure, weather proofing, sound proofing, heat insulation, further isolation effect between adjacent spaces (e.g. adjacent rooms) or any combination thereof. In various embodiments, the horizontal cover 1110 may be connected with a beam connecting two horizontal structural frames using a unused elongated groove of the beam (e.g. an elongated groove that is not connecting structural frames).

According to embodiments, the horizontal cover 1110 may include the covering skin 1111, the body 1112 and the elongated protrusion 1113. The covering skin 1111 can be configured to hid the sunken space (e.g. channel) between two adjacent horizontal structural frames, as illustrated in FIG. 11D. While the size of the covering skin 1111 can be varied depending on applications, according to some embodiments, the size of the covering skin 1111 is large enough to cover both the sunken space and at least part of the horizontal structural frames. However, in terms of length, the length of the covering skin 1111 can be configured to be substantially equal to the length of the two adjacent horizontal structural frames.

The body 1112 is configured to partly or entirely fill the sunken space (e.g. channel) between two adjacent horizontal structural frames. In some embodiments, the body 1112 may be a polygon tube with a hollow inside. The hollow structure of the body 1112 may not cause a structural weakness as the horizontal cover 1110 can be considered to be aesthetic and typically is not be designed to provide structural strength to the building module. In some embodiments, the body 1112 may be complementary to the sunken space (e.g. channel) between two adjacent horizontal structural frames, in shape and dimensions. In this embodiment, the width and thickness of the body 1112 (i.e. width and thickness of the polygon tube) may be substantially equal to width and depth of the sunken space (e.g. channel) between two adjacent horizontal structural frames.

The elongated protrusion 1113 is configured to be inserted into the unused elongated groove of the beam connecting two horizontal structural frames. In various embodiments, the depth of the elongated protrusion 1113 is substantially equal to the depth of the unused elongated groove of the connecting beam. However, in some embodiments, the elongated protrusion 1113 is not fully complementary to the unused elongated groove of the connecting beam in shape.

FIG. 11D illustrates a side view of a horizontal cover connected to a beam connecting two horizontal structural frames, in accordance with embodiments. Referring to FIG. 11D, the horizontal cover 1110 can be clipped on the beam 1120 which connects the two horizontal structural frames 1130. Specifically, the elongated protrusion 1113 of the horizontal cover 1110 can be inserted into and therefore being held in place by the elongated groove 1125 of the beam 1120. In some embodiments, the elongated protrusion 1113 of the horizontal cover 1110 can be permanently inserted into the elongated groove 1125 of the beam 1120 and therefore the horizontal cover 1110 may not be removed from the beam 1120 without damage caused thereto. In some embodiments, the elongated protrusion 1113 of the horizontal cover 1110 is inserted into the elongated groove 1125 of the beam 1120 such that the horizontal cover 1110 may be removed from the beam 1120 for potential reuse.

Further referring to FIG. 11D, the body 1112 can fill the channel 1140 (e.g. sunken space) between two adjacent horizontal structural frames 1130. The body 1112 can be a hollow structure, while this configuration does not cause a structural weakness as the horizontal cover 1110 is not designed to provide any structural strength to the building module. The body 1112 can be partly complementary to the channel 1140 (e.g. sunken space) in shape and dimensions. Specifically, the width and the thickness of the body 1112 can be substantially equal to width and depth of the channel 1140 (e.g. sunken space).

Further referring to FIG. 11D, the horizontal cover 1110 is configured to hide and cover the channel 1140 (sunken space) between two adjacent horizontal structural frames 1130. The covering skin 1111 can hide and cover the channel 1140. As illustrated in FIG. 11D, the size of the covering skin 1111 can be sufficiently large in order to cover both the channel 1140 and part of the horizontal structural frames 1130. In terms of length, while not shown in the figure, the length of the covering skin 1111 can be substantially equal to the length of the two horizontal structural frames 1130.

FIG. 11E illustrates an elevation view of a vertical cover in accordance with embodiments. According to embodiments, the vertical cover 1150 is configured to hide and cover the channel (sunken space) between two adjacent vertical structural frames, thereby providing a more seamless look on the walls (e.g. more flattened wall) and aid to minimize potential safety concerns. The vertical cover 1150 may also provide for example enclosure, weather proofing, sound proofing, heat insulation, further isolation effect between adjacent spaces (e.g. adjacent rooms) or any combination thereof. In various embodiments, the vertical cover 1150 may be connected with a beam connecting two vertical structural frames using an unused elongated groove of the beam (e.g. elongated groove that is not connecting structural frames).

According to embodiments, the vertical cover 1150 may include the covering skin 1151, the body 1152 and the elongated protrusion 1153. The covering skin 1151 is a portion hiding the sunken space (e.g. channel) between two adjacent vertical structural frames, as illustrated in FIG. 11F. While the size of the covering skin 1151 can be varied depending on applications, according to some embodiments, the size of the covering skin 1151 can be sufficiently large to cover both the sunken space and at least part of the vertical structural frames. However, in terms of length, the length of the covering skin 1151 can be substantially equal to the length of the two adjacent vertical structural frames.

The body 1152 is configured to partially or entirely fill the sunken space (e.g. channel) between two adjacent vertical structural frames. In some embodiments, the body 1152 may be a polygon tube with hollow inside. The hollow structure of the body 1152 may not result in a structural weakness as the vertical cover 1150 may not provide any structural strength to the building module. In some embodiments, the body 1152 may be complementary to the sunken space (e.g. channel) between two adjacent vertical structural frames, in shape and dimensions. For example the width and thickness of the body 1152 (i.e. width and thickness of the polygon tube) may be substantially equal to width and depth of the sunken space (e.g. channel) between two adjacent vertical structural frames.

The elongated protrusion 1153 can be configured to be inserted into the unused elongated groove of the beam connecting two vertical structural frames. In various embodiments, the depth of the elongated protrusion 1153 can be substantially equal to the depth of the unused elongated groove of the connecting beam. However, the elongated protrusion 1153 does not have to be complementary to the unused elongated groove of the connecting beam in shape.

FIG. 11F illustrates an elevation view of a vertical cover connected to a beam connecting two vertical structural frames, in accordance with embodiments. Referring to FIG. 11F, the vertical cover 1150 is clipped on the beam 1160 which connects the two vertical structural frames 1170 in a way illustrated above. Specifically, the elongated protrusion 1153 of the vertical cover 1150 is inserted into and therefore being held in place by the elongated groove 1165 of the beam 1160. In some embodiments, the elongated protrusion 1153 of the vertical cover 1150 is permanently inserted into the elongated groove 1165 of the beam 1160 and therefore the vertical cover 1150 cannot be removed from the beam 1160 without demolition. In some embodiments, the elongated protrusion 1153 of the vertical cover 1150 is inserted into the elongated groove 1165 of the beam 1160 such that the vertical cover 1150, at any time, can be removed from the beam 1160 without demolition.

Further referring to FIG. 11F, the body 1152 is filling the channel 1180 (e.g. sunken space) between two adjacent vertical structural frames 1170. The body 1152 has a hollow structure however this configuration does not cause a structural weakness as the vertical cover 1150 is not designed to provide any structural strength to the building module. The body 1152 is partly complementary to the channel 1180 (e.g. sunken space) in shape and dimensions. Specifically, the width and the thickness of the body 1152 can be substantially equal to the width and depth of the channel 1180 (e.g. sunken space).

Further referring to FIG. 11F, the vertical cover 1150 can be configured to hide and cover the channel 1180 (sunken space) between two adjacent vertical structural frames 1170. The covering skin 1151 can hide and cover the channel 1180. As illustrated in FIG. 11F, the size of the covering skin 1151 can be sufficiently large to cover both the channel 1180 and part of the vertical structural frames 1170. In terms of length, while not shown in the figure, the length of the covering skin 1151 can be substantially equal to the length of the two vertical structural frames 1170.

It will be readily understood that each of the external corner cover, internal corner cover, edge cover (e.g. external corner cover, internal corner cover and edge cover illustrated in FIGS. 10A to 10C, respectively) are similarly configured to be connected with the beam as illustrated above for the horizontal and vertical covers, and these connections will be also be considered to be within the scope of the instant application.

According to some embodiments, a panel may be affixed to the structural frame using a chemical locking system. In some embodiments, a chemical locking system can be configured as a chemical mixture which upon activation thereof enables the affixing of the desired components. For example, a chemical locking system can be configured as a glue, polyurethane foam or other chemical system that can provide a desired locking force as would be readily understood. FIGS. 12A to 12D illustrate examples for securing a panel to a structural frame using a chemical locking system, in accordance with embodiments. FIG. 12A illustrates, in an exploded perspective view, a panel to be secured to a structural frame using a chemical locking system, in accordance with embodiments. FIGS. 12B and 12C illustrate, in a perspective view, a chemical locking system attached to a structural frame, in accordance with embodiments. FIG. 12D illustrates, in a cross section view, a panel secured into a structural frame using a chemical locking system, in accordance with embodiments.

Referring to FIGS. 12A to 12D, one or more chemical locking systems 1220 which can be configured to secure the panel 1230 to the vertical structure frame 1210. The chemical locking system 1220 may be configured to be inwardly attached to one or more lateral sides of the vertical structural frame 1210 and outwardly attached to one or more edges of the panel 1230. In one example, as illustrated in FIGS. 12A and 12D, the chemical locking system 1220 can be configured as one or more bags or containers with chemical mixtures, therein and can be configured to be placed between the internal surface of longer lateral sides of the vertical structural frame 1210 and the external surface of longer edges of the panel 1230.

According to embodiments, the chemical locking system 1220 may be a glue, polyurethane foam or other chemical component or combination of chemical components. In various embodiments, the chemical locking system 1220 may comprise one or more chemical components. For example, the chemical locking system can be configured as two separate components and position and positioned within members to be connected, wherein these two components are combined thereby activating the chemical locking system when desired. As illustrated in FIGS. 12A and 12C, the chemical locking system has a first portion 1221 and a second portion 1222, for combination when locking is desired. For instance, in some embodiments, the chemical locking system may be ELASTOPOR® Rigid Polyurethane Foam System, manufactured by BASF Corporation (Florham Park, N.J.) which comprises a first component being a polyol resin component (e.g., ELASTOPOR® P 15390R Resin) and a second portions being an isocyanate component (e.g. ELASTOPOR® P 1001U Isocyanate), or other equivalent polyurethane foam system. The chemical components of the polyurethane foam system may be contained in a bag made of an appropriate material (e.g. ESP-5001 C white foil laminated film). Each bag of the polyurethane foam system may comprise 83 ml of the polyol resin component and 83 ml of the isocyanate component, in total 166 ml of chemical components. Upon mixing thereof, the example chemical locking system provided thereby can be activated.

According to embodiments, to secure the panel 1230 into the vertical structural frame 1210 using the chemical locking system 1220, the top of the chemical locking system 1220 (e.g. top of the chemical bag comprising polyol resin component and isocyanate component) may be attached into the top of the inlet of the lateral sides of the vertical structural frame 1210, as illustrated in FIG. 12B. Here, it is noted that the top of the chemical locking system 1220 may be an end where the two chemical components, namely the first portion and the second portion 1221 and 1222 are not placed, as illustrated in FIG. 12B. The bottom of the chemical locking system 1220 may be the other end where the chemical components are located, as illustrated in FIG. 12C. Once the chemical locking system 1220 is attached, the pouch bags containing the chemical components (e.g. a polyol resin component and an isocyanate component) may be opened (e.g. breaking the seal) at the same time so that the chemical components e.g. first portion and second portion 1221 and 1222 can be mixed. The chemical components may be mixed for a period instructed by the product manual (e.g. 40 seconds). Then, the bottom of the chemical locking system 1220 may be attached into the bottom of the inlet of the lateral sides of the vertical structural frame 1210. In some embodiments, the bottom of the chemical locking system 1220 may be attached into the frame before mixing the chemical components and in the chemical locking system 1220. When the chemical locking system 1220 with mixed chemical components is appropriately attached into the top and bottom of the inlet of the frame 1210, the panel 1230 will be placed inside of the vertical structural frame 1210 (e.g. the panel 1230's four edges are inwardly affixed to four lateral sides of the structural frame 1210), and hold the panel 1230 until it is securely affixed to the structural frame 1210 (e.g. approximately for 2 minutes). Upon activation of the chemical process, the mixed chemical component (e.g. polyurethane foam) of the chemical locking system 1220 will make an expanded chemical foam thereby securing the panel 1230 into place. In some embodiments, friction between the expanded chemical foam (e.g. expanded polyurethane foam), the structural frame 1210 and the panel 1230 may enable the panel 1230 to being secured. In various embodiments, the chemical locking system 1220 may be capable of holding the panel 1230 in position against substantial force. A cross section view of the panel 1230 being secured into the structural frame 1210 is illustrated in FIG. 12D.

According to embodiments, the panel 1230 which is securely affixed to the structural frame 1210 using the chemical locking system 1220 can be removed from the frame 1210. The expanded chemical component (e.g. expanded foam) may be cut, for example through the use of a utility knife or other appropriate cutting tool, along the edges of the panel 1230 and the frame 1210 on both sides. Upon the cutting of the chemical locking system, the panel 1230 can be separated from the frame 1210 by pushing the panel 1230 out of the frame 1210.

It will be readily understood that while a vertical structural frame is illustrated in FIGS. 12A to 12D, a panel can be similarly secured into a horizontal structural frame as illustrated above for the vertical structural frame, and such securing will be also considered to be within the scope of the instant application.

Potential advantages of some embodiments include construction time reduction, flexibility and adjustability in design and use, and extendibility of the building structural module in a horizontal and vertical manner. For example, time required for building up one room is only expected to take a few hours. With a traditional construction method, it would have taken up to several weeks or months to build the same room. This is an enormous amount of time reduction which would also result in huge cost saving, especially labour cost saving.

Although the present invention has been described with reference to specific features and embodiments thereof, it is evident that various modifications and combinations can be made thereto without departing from the invention. The specification and drawings are, accordingly, to be regarded simply as an illustration of the invention as defined by the appended claims, and are contemplated to cover any and all modifications, variations, combinations or equivalents that fall within the scope of the present invention. 

We claim:
 1. A horizontally and vertically extendable building structure module comprising: a panel; a structural frame with one or more elongated connectors on each lateral side, the structural frame being configured to hold the panel; and one or more beams with one or more elongated mating connectors on each lateral side, the beams being configured to connect and align the structural frames by interconnecting the elongated connector and the elongated mating connector, wherein the building structure module is configured to build a building structure without additional structural support.
 2. The building structure module of claim 1, wherein the one or more elongated connectors is an elongated protrusion extending outwardly and wherein the one or more elongated mating connectors is an elongated groove.
 3. The building structure module of claim 1, wherein the structural frame and the beam are capable of being connected and disconnected multiple times.
 4. The building structure module of claim 1, the panel comprising: an internal frame; a collection of hexagonal prismatic cells surrounded by the internal frame; and a skin covering the internal frame and the collection of hexagonal prismatic cells.
 5. The building structure module of claim 4, wherein the hexagonal prismatic cells are filled with insulating materials.
 6. The building structure module of claim 1, wherein the structural frame is shaped in rectangle.
 7. The building structure module of claim 2, wherein the elongated protrusion is configured to be complementary to the elongated groove in shape and size.
 8. The building structure module of claim 2, wherein head of the elongated protrusion is larger than body of the elongated protrusion.
 9. The building structure module of claim 8, wherein the elongated protrusion is a T-shaped extrusion and the elongated groove is a T-slot rail.
 10. The building structure module of claim 1, wherein the beam is shaped in rectangular prism.
 11. The building structure module of claim 1, wherein interior of the beam is at least partly hollow.
 12. The building structure module of claim 11, wherein the beam is filled with materials providing more rigidity.
 13. The building structure module of claim 11, wherein the beam is filled with insulating materials.
 14. The building structure module of claim 1, wherein the panel is a floor, a ceiling or a roof.
 15. The building structure module of claim 1, wherein the panel comprises one or more of a wall, window and door.
 16. The building structure module of claim 1, wherein the panel is made of one or more of wood, concrete and metal.
 17. The building structure module of claim 1, wherein the structural frame is made of one or more of wood, concrete and metal.
 18. The building structure module of claim 1, wherein the one or more beams are made of one or more of wood, concrete and metal.
 19. The building structure module of claim 1 further comprising: one or more covers with one or more elongated connecting components, each cover being configured to connect one of the one or more beams by interconnecting the elongated connecting component and the elongated mating connector.
 20. The building structure module of claim 1, wherein the structural frame secures the panel using chemical locking system.
 21. The building structure module of claim 20, wherein the chemical locking system comprises a plurality of chemical components, the plurality of chemical components, upon mixing, generating chemical foam. 